Collapsible cellular carton



Nov. 29, 1955 w. H. INMAN COLLAPSIBLE CELLULAR CARTON l t e e h s k. t e e h s 2 9 9 7 4 4 2 L a- 2 s W: I 1 y. 5 3. 81. m 5, J 2 327 w 5 UmFm. u v. F 5 U I INVEN TOR. WILLIAM H. l/VMAN HIS A TTORIIEY Nov. 29, 1955 w. H. lNMAN COLLAPSIBLE CELLULAR CARTON 2 Sheets-Sheet 2 Filed Jan. 5, 1955 IN V EN TOR. WILLIAM H. lNMA/V HIS ATTORNEY United States Patent COLLAPSmLE CELLULAR CARTON William H. Inman, Newark, N. Y., assignor to Bloomer Bros. Company, Newark, N. Y., a corporation of New York Application January 5, 1953, Serial No. 329,621

Claims. (Cl. 22928) This invention relates to cellular cartons of the variety made from cardboard or other suitable sheet material, for containing eggs or other fragile articles, one object of the invention being to provide an improved carton of the above character having a more simple, practical and efficient construction affording a high degree of strength and resistance to crushing, particularly under vertical pressure on the carton or the contents thereof.

Another object is to provide a carton having the above advantages which is capable of being readily cut from sheet material, scored for folding, folded and glued in collapsed condition, and of being easily swung to erected condition by automatic machines of known construction.

A further object is to provide a carton of the above character having a form of construction which eliminates externally-projecting supporting legs or other irregular projections and presents smooth outer wall surfaces when in erected condition so as to obviate entanglement with one another and to facilitate the stacking of quantities of the filled cartons.

Still a further object is to provide a carton having the above advantages which requires a minimum amount of material in proportion to its strength and which is capable of being readily and economically manufactured.

To these and other ends the invention resides in certain improvements and combinations of parts, all as will be hereinafter more fully described, the novel features being pointed out in the claims at the end of the specification.

In the drawings:

Fig. 1 is a plan view of a blank of sheet material cut, scored and glued, in accordance with my invention, preparatory to folding;

Fig. 2 is an enlarged fragmentary plan view of the top wall of the carton as shown in Fig. 1;

Fig. 3 is a fragmentary, perspective view of the carton in partially folded position showing the joining of the outer bottom wall sections;

Fig. 4 is an end elevation showing the completed carton in the process of erection;

Fig. 5 is a reduced perspective view showing the carton in erected condition;

Fig. 6 is an end elevation of the erected carton;

Fig. 7 is a fragmentary, sectional plan view substantially along the line 77 in Fig. 6, and

Fig. 8 is a fragmentary, sectional end elevation substantially along the line 88 in Fig. 7.

This invention is an improvement on the general type of carton disclosed in my prior Patent No. 2,556,088, for the purpose of producing a stronger and more practical, economical and convenient carton.

The embodiment of the present invention, herein disclosed by way of illustration, preferably comprises a onepiece blank, shown generally at 21, of cardboard or other suitable sheet material cut, scored and glued for folding, as shown in Fig. 1. The blank is shown in Fig. 1 with the outer surfaces of the carton uppermost in order to more clearly show the various cut and score lines which form the parts of the carton, hereinafter described. The

Cit

blank is of generally rectangular shape adapted to be economically cut from stock material, and comprises in order, as shown in Fig. 1, a locking flap 23, cover 25, a rear wall 27, outer bottom plies 29 and 31, an inner bottom wall 33, longitudinal partition sections 35 and 37, an inner bottom wall 39, outer bottom plies 41 and 43, a front wall 45, top wall 47, and an attaching strip 49.

The above sections of the blank are separated by score lines extending across the blank, as shown by multiple lining in the drawings, to facilitate folding, as well understood in the art. The top wall 47 is cut and scored for the down folding of a series of cross partitions having three diiferent configurations, as shown at 51, 52 and 53 (Fig. 1), for separating the carton longitudinally into cells.

Thus the blank is cut through along lines 54 and scored along the lines 55 to permit the downfolding of the cross partitions, as shown in Fig. 5, for coaction with a 1ongitudinal partition, hereafter described, to divide the carton into a dozen article-receiving cells. The blank is cut out, as at 57, between the cross partitions to free the lower edges thereof which are notched or slitted centrally, as at 59, for engagement with the longitudinal par tition. Short cuts 61 give flexibility to the side edges of slits 59 to assist in the frictional engagement of the cross partitions with the longitudinal partition, as disclosed in my prior Patents Nos. 2,277,327 and 2,556,088. The four cross partitions adjacent the right end of the blank, as viewed in Fig. 1, fold downwardly in a counterclockwise direction to their erected positions shown in Fig. 5, while the three partitions at the other end of the carton are arranged to swing in a clockwise direction to their erected positions shown in Fig. 5. Each cross partition is centrally scored longitudinally of the carton, as at 63, in addition to slits 59, to facilitate the central folding of the transverse partitions in the collapsed condition of the carton, as hereafter more fully described.

The longitudinal partition sections 35 and 37 are formed with cut-out portions or notches, as at 65 (Fig. 1) to provide, when erected, a series of notches in the upper portion of the longitudinal partition. Notches are open at the upper ends thereof to allow the cross or transverse partitions to be swung down and engage the lower portion of the longitudinal partition in the slits 59 thereof. Sections 35 and 37 are separated by an interrupted score line 67 (Fig. 1) extending longitudinally of the carton to assist in reversely folding the partition sections to their positions shown in Figs. 4-6, inclusive. Sections 35 and 37 are separated from the adjacent inner bottom sections 33 and 39, respectively, by interrupted score lines 69 and 71, for facilitating the folding of the bottom sections relative to the adjacent longitudinal partition sections. A series of U-shaped cuts 73 (Fig. 1) connect adjacent segments of score line 69 and forms a series of spaced tab portions 75 (Figs. 1 and 6) cut out of bottom section 33, which form extensions of longitudinal partition section 35 and project downwardly therefrom, forming supporting means or feet in the erected position of the parts, as shown in Fig. 6. A series of similar U-shaped cuts 77 (Fig. 1) connect segments of score line 71 for forming a series of spaced feet 79 (Fig. 6) similar to feet 75. Feet 75 and 79 are preferably so spaced as to abut one another in the folded and erected condition of the carton, as shown in Figs. 4 and 6.

Inner bottom wall 33 is separated from outer bottom upper ply 31 by a score line 81 for facilitating the folding of ply 31 at an angle thereto, as shown in Fig. 6. Bottom ply 31 is separated from outer bottom lower ply 29 by an interrupted fold line 83 (Fig. 1), segments of which are connected by a series of U-shaped cuts 85,

as shown in Fig. 1, forming a series of spaced tab por.

tions 87 (Fig. 3). As bottom plies 31 and 29 are Patented Nov. 29, 1955 reversely folded into superposed position, for forming a lower. bottom. section shown generally at 89 (Fig. 6), tabs 87 form extensions thereof as shown in Fig. 3. Inner bottom wall 39 is separated from outer bottom upper ply 41 by ascore line 91 (Fig. 1). Bottom ply 41 in turn is separated from outer bottom lower ply 43 by an interrupted fold line 93 (Fig. l), spaced segments of which are connected by a series of U-shaped cuts 95 formi'n'ga series of spaced tab portions 97 (Fig. 1). As bottom plies 41 and 43 are reversely folded into superposed position for forming a lower bottom section shown generally at 99 (Fig- 6), tab portions 97 form extensions of said section, as shown in Fig. 3. Tabs 87 are so spaced as to pass through the openings in bottom ply 41 formed by the cutting out of tabs 97 which, in turn, pass through the openings in outer ply 29 formed by the cutting out of tabs 87, as shown in Fig. 3, when the bottom sections are brought into abutting position as shown in Pi gs. 7 and 8.

Glue, or other suitable adhesive, is preferably applied to the upper surfaces of longitudinal sections 35 and 37 (as viewed in Fig. 1), as at 191 (Fig. 1). Bottom ply 29 is preferably provided with a strip of glue or other suitable adhesive, as at 103, on the underside thereof, as viewed in Fig. l, for securing said ply to upper ply 31 when the same are reversely folded to superposed position in the formation of outer bottom section 89. Although the adhesive may be applied to the undersurface of either ply 29 or 31, I prefer to apply it to ply 29 before tabs 87 are swung out of alignment therewith so that in one step I may apply sufficient glue for securing said upper and lower plies together and placing sufficient giue upon tabs 87 to secure the same to the outer ply 43' of the opposite bottom section 99. Similarly, bottom ply 41 is preferably provided with a strip of glue, as at 105 (Fig. l), for adhesively securing said upper ply 41' and lower ply 43 in superposed position for forming bottom section 99'. In the same operation tabs 97 have adhesive placed thereon for securing the same to the undersurface of bottom ply 31 when the parts are glued together, as shown in Fig. 6. Rear wall 27 is preferably provided on the undersurface thereof, as viewed in Fig. l, with a strip of glue or other suitable adhesive, as at 107 (Fig. l), for adhesively securing attaching strip 49 thereof when the carton is folded and glued as shown in Figs. 4 and 6.

In the folding of the blank, it is first broken along score lines 81 and 91 which separate the inner bottom walls from the respective upper plies of the lower bottom sections. Longitudinal partition sections 35 and 37 are then reversely folded about fold line 67 and brought into superposed position for forming a doublethickness, longitudinal partition. Bottom plies 41 and 43 are then reversely folded along fold line 93 and bottom plies 31 and 29 reversely folded along fold line 83 for forming outer bottom sections 99 and 89, respectively. Thereafter, bottom sections 99 and 89 are brought into abutting position, substantially in the same plane, as shown in Fig. 8, so that tabs 87 slide into the openings formed in ply 41 by the cutting out of tabs 97, as shown in Fig. 3. Because of the adhesive on the undersurface of tabs 87 and/ or the adhesive on the upper surface of bottom ply 43, tabs 87 securely adhere to ply 43. Similarly, tabs 97 slide into the openings in ply 29 resulting from the formation of tabs 87, as shown in Figs. 3 and 7, and are glued to the undersurface of ply 31 by the adhesive deposited on said tabs during the gluing steps described above. Thus, tabs 87' and 97 hold bottom sections 89 and 99 in abutting relationship while providing a hinged connection therebetween in such a manner that bottom sections 89 and 99 may swing into contact with each other when the carton is moved into collapsed position. This folding movement of the outer bottom sections can be" seen froman inspection of the carton in fully-erected position, as in Fig. 6, and its partially-collapsed position shown in Fig. 4.

Front wall 45 is then folded relative to bottom section 99 about a score line 199 (Fig. 1) and top wall 47 folded relative to front wall 45 along a longitudinally-extending irregular fold line formed in part by the series of spaced cuts 54, the series of spaced fold lines 55 and a series of spaced short cuts or slits 111 (Fig. 1) located as in Fig. 2, which separate the transverse partitions from the front wall of the carton. This swings the top wall over the longitudinal partition and the top wall is then reversely folded along fold line 63 over the upper ends of the longitudinal partition which project upwardly through slits 59 in the corresponding transverse partitions. Thereafter, the carton is collapsed to substantially fiat position and rear wall 27 folded relative to bottom section 89 along a fold line 113 (Fig. 1), thereby bringing the bank of glue 107 on the inner surface thereof into contact with attaching strip 49 for securing the same thereto, for completing the folding and gluing of the carton.

In erecting the carton for use, as indicated in Fig. 4-, the longitudinal partition 35, 3-7 is preferably forced downwardly, pressing downwardly and outwardly on inner bottom walls 33 and 39 which spread the outer bottom sections 89 and 99' and force the same into substantially coplanar relationship, as shown in Fig. 6. The downward movement of the longitudinal partition is arrested by feet 75 and 79 engaging the outer bottom sections along the line of juncture therebetween, as shown in Fig. 6. The spreading of the bottom sections 89 and 99' also spreads front and rear walls and 27 and pulls the transverse partitions, while still in substantially horizontal position downwardly partially into the corresponding notches 65 of the longitudinal partition.

At this point, cross partitions 51, 52 and 53 are swung downwardly about their fold lines 114 (Fig. 2) which in conjunction with intersecting adjacent fold lines 55 form substantially triangular hinge portions 115, as shown in Fig, 2. In this erecting movement, the cross partitions swing downwardly in notches 65 and straddle and frictionally engage the lower portion of the longitudinal partition in their slits 59. Partitions 51 and 52 are preferably shaped so that the lower edges thereof engage the upper surfaces of inner bottom walls 33 and 39 for increasing the frictional engagement of the carton parts in the erected position thereof. Partitions 51 are preferably formed with laterally-extending lugs or projections 117 (Fig. 2) which engage the inner surfaces of the front and rear walls for increasing the frictional engagement between the transverse partitions and the front and rear walls, Partitions 52"have short diagonally-extending slits 119 (Fig. 2) formed therein for forming a pair of substantially triangular-hearing lugs 121 (Fig. 2) which bend relative thereto during the erection of the carton for increasing the area of contact and frictional engagement between transverse partitions 52 and the front and rear walls of the carton. Partitions 51 have a series of perforated fold lines 123 formed therein, as shown in Fig. 2, for allowing the partition to buckle or bow outwardly between the longitudinal partition and the front and rear walls of the carton, thereby increasing the longitudinal spacing between partitions 51 and the adjacent ones of partitions 52 for increasing the longitudinal length of the end cells.

The openings formed by the down turning of feet 75 and 79 from inner bottom walls 33 and 39, respectively, serve to ventilate the cells by connecting them with the space between the inner and outer bottom sections.

The parts are thus brought to their erected positions shown in Figs. 5 and 6, from which it will be seen that the bottoms of the cells are formed by the inner bottom walls 33 and 39 which are inclined inwardly and upwardly from their outer to their inner edges at a substantial' angle to the horizontal outer bottom sections 89iand 99, so as" to provide the cells with resilientlycushioned bottom walls on which eggs or other fragile articles are effectively supported and protected against impacts and crushing. This inclined disposition of the inner bottom walls supports one longitudinal edge of each wall on the outer bottom sections while providing substantial cushioning separation therefrom with 'a minimum of overall height and material and tends to tip the articles outwardly and away from one another. Bottom walls 33 and 39 are supported adjacent the inner edges thereof by the longitudinally-extending series of supporting means or feet 75 and 79 which rest on the outer bottom sections. Bottom sections 89 and 99 tie together the bottoms of the front and rear side walls and the outer edges of the inner cushioning walls 33 and 39, and in conjunction with feet 75 and 79 and cushioning Walls 33 and 39 form a substantially triangular, truss-like structure having a strong and highly rigid construction capable of resisting shocks and impacts and substantial crushing forces, especially those in a vertical direction, as for example, those imposed by the stacking of the cartons one upon another.

In addition to the above truss relationship, the carton has the further advantage that inner bottom walls 33 and 39 may yield under impact or pressure thereby absorbing the force and effectively cradling the eggs. Not only does this truss relationship increase the strength of the Walls 33 and 39, without decreasing the cushioning action thereof, but it provides substantial support for the longitudinal partition which is preferably of such a height as to engage the center of the cover when in the closed position.

The rear side wall 27 is extended upwardly substantially level with the top of the longitudinal partition and hingedly supports the rear edge of cover 25. Flange 23, Which is attached along the front or free edge of cover 25, is provided with a series of hooks 125 and a tab 127 (Fig. 1) which, when the carton is closed, engage under and between the hinge portions 115 of the cross partitions. The cover is supported longitudinally along the rear edge thereof by rear wall 27 and along the front edge thereof by the engagement between flange 23 and front wall 45. In addition, I have found it advantageous to extend the longitudinal partition to such an extent as to engage and support the cover longitudinally adjacent the center thereof when the cover is folded to closed position, as shown by broken lines in Fig. 6, thereby increasing the strength of the carton and resistance of the cover to crushing forces. As the longitudinal partition, through feet 75 and 79, extends into engagement with the outer bottom sections $9 and 99, it has greatly increased strength and causes vertical impacts to be transferred from the cover to the outer bottom of the carton without affecting the eggs or other contents.

The parts are preferably so constructed that the longitudinal partition is of greater height than the transverse partitions, both in the erected condition of the carton, as shown in Fig. 6, and also in the collapsed position where the upper ends of the longitudinal partition extend upwardly through slits 59 in the corresponding transverse partitions. The upward projection of the longitudinal partion through the reversely folded transverse partitions in partially collapsed position of the carton is shown in Fig. 4. This is an important advantage, for it insures that once the folding and gluing of the carton is completed, the various parts will remain in their proper position and alignment so that the carton may thereafter be easily swung to erected position, and if desired, back to collapsed position. This construction eliminates the need for special handling, operations or special erecting machines.

It will be further noted that as feet 75 and 79 are lo cated inside the outer bottom walls 89 and 99, there are no depending projections which are likely to become engaged or entangled with other cartons and interfere with the compact stacking of the cartons.

Thus, it will be seen that my invention provides an improved carton having a high degree of strength and rigidity, especially to vertical forces, which may be accomplished by construction of a minimum of material. The

carton has a further advantage in that it may be readily and economically manufactured and collapsed for shipment into compact, flat shape, and thereafter may be easily and conveniently erected by hand or by mechanical erecting devices, to its erected position shown in Figs. 5

-and 6, since the top wall and longitudinal partition are continuously engaged and guided in movement upon each other.

It will thus be seen that the invention accomplishes its objects and, while it has been herein disclosed by reference -t0 the details of a preferred embodiment, it is to be understood that such disclosure is intended in an illustrative, rather than a limiting sense, as it is contemplated that various modifications in the construction and arrangement of the parts will readily occur to those skilled in the art,

.- .within the spirit of the invention and the scope of the appended claims.

I claim:

1. A cellular carton comprising a blank of sheet material cut, scored and folded to form front and rear side walls, a pair of outer bottom sections having lower plies hingedly connected to said side walls along the lower edges thereof and extending inwardly into proximity with each other and connected together, said outer bottom sections having upper plies hingedly connected to the respective lower plies along the inner edges thereof and extending outwardly adjacent said side walls, inwardly and upwardly inclined inner cushioning bottom sections hingedly connected to the respective upper plies of said outer bottom sections adjacent the junction of said outer bottom sections and said side walls, respectively, and

' extending into engagement with each other, upwardly extending longitudinal partition sections hingedly connected to the respective inner cushioning sections adjacent the upper edges thereof for forming a central longitudinal partition of double thickness, said partition sections being hingedly connected to each other along the upper edges thereof, and a top wall hinged to and connected with said front and rear walls and having therein a series of transverse partitions hingedly connected thereto and folded downwardly therefrom between said side walls and on opposite sides of said longitudinal partition to provide a plurality of cushioned article-receiving cells.

2. A cellular carton comprising a blank of sheet material cut, scored and folded to form front and rear side walls, a cover hinged to said rear wall, a pair of outer bottom sections having lower plies hingedly connected to said side Walls along the lower edges thereof and extending inwardly into proximity with each other and connected together, said outer bottom sections having upper plies hingedly connected to the respective lower plies along the inner edges thereof and extending outwardly adjacent said side walls, inwardly and upwardly inclined inner cushioning bottom sections hingedly connected to the respective upper plies of said outer bottom sections adjacent the junction of said outer bottom sections and said side walls, respectively, and extending into engagement with each other, upwardly extending longitudinal partition sections hingedly connected to the respective inner cushioning sections adjacent the upper edges thereof for forming a central longitudinal partition of double thickness having its upper edge located in supporting proximity to said cover, said partition sections being hingedly connected to each other along the upper edges thereof, and a top wall hinged to and connected with said front and rear walls and having therein a series of transverse partitions hingedly connected thereto and folded downwardly therefrom between said side walls and on op posite sides of said longitudinal partition to provide a plurality of cushioned article-receiving cells.

3. A cellular carton comprising a blank of sheet material cut, scored and folded to form front and rear side walls, a pair of outer bottom sections having lower plies hingedly connected to said side walls along the lower edges thereof, said outer bottom sections extending inwardly into proximity with each other and being hingedly connected together, said outer bottom sections having upper plies hingedly connected to the respective lower plies along the inner edges thereof and extending outwardly adjacent said side walls, inwardly and upwardly inclined inner cushioning bottom sections hingedly connected to the respective upper plies of said outer bottom sections adjacent the junction of said outer bottom sections and said side walls, respectively, and extending substantially into engagement with each other, upwardly extending longitudinal partition sections hingedly connected to the respective inner cushioning sections adjacent the upper edges thereof for forming a central longitudinal partition of double thickness, said partition sections being hingedly connected to each other along the upper edges thereof, and a top wall hinged to said front wall and foldably connected with said rear wall, said top wall having therein a series of transverse partitions hingedly connected thereto and folded downwardly therefrom between said side walls and on opposite sides of said longitudinal partition to provide a plurality of cushioned articlereceiving cells, said top wall being formed with a central longitudinal score line, whereby said top wall and transverse partitions may be folded upwardly in continuous engagement with said longitudinal partition while said bottom sections are foldable downwardly centrally about said hinge connection therebetween for collapsing said carton to substantially flat condition.

4. A cellular carton comprising a blank of sheet material cut, scored and folded to form front and rear side walls, a pair of outer bottom sections having lower plies hingedly connected to said side walls along the lower edges thereof and extending inwardly into proximity with each other and connected together, said outer bottom sections having upper plies hingedly connected to the respective lower plies along the inner edges thereof and extending outwardly adjacent said side walls, inwardly and upwardly inclined inner cushioning bottom sections hingedly connected to the respective upper plies of said outer bottom sections adjacent the junction of said outer bottom sections and said side walls, respectively, and extending into engagement with each other, upwardly extending longitudinal partition sections hingedly connected to the respective inner cushioning sections adjacent the upper edges thereof for forming a central longitudinal partition of double thickness, said partition sections being hingedly connected to each other along the upper edges thereof, a top wall hinged to and connected with said front and rear walls and having therein a series of transverse partitions hingedly connected thereto and folded downwardly therefrom between said side walls and on opposite sides of said longitudinal partition to provide a plurality of cushioned article-receiving cells, and supporting means depending from said longitudinal partition below said inner cushioning walls for engagement with said outer bottom sections, said supporting means, inner cushioning walls and outer bottom sections forming a relatively rigid, truss-like support of substantially triangular shape for firmly supporting said inner cushioning bottom walls and longitudinal partition with a smooth outer bottom surface for said carton.

5. A cellular carton comprising a blank of sheet material cut, scored and folded to form front and rear side walls, a cover hinged to said rear wall, a pair of outer bottom sections having lower plies hingedly connected to said side walls along the lower edges thereof and extending inwardly into proximity with each other and connected together, said outer bottom sections having upper plies hingedly connected to the respective lower plies along the inner edges thereof and extending outwardly adjacent said side walls, inwardly and upwardly inclined inner cushioning bottom sections hingedly connected to the respec tive upper plies of said outer bottom sections adjacent the junction of said outer bottom sections and said side walls, respectively, and extending into engagement with each other, upwardly extending longitudinal partition sections hingedly connected to the respective inner cushioning sections adjacent the upper edges thereof for forming a central longitudinal partition of double thickness having its upper edge located in supporting proximity to said cover, said partition sections being hingedly connected to each other along the upper edges thereof, a top 'wall. hinged to and connected with said front and rear walls and having therein a series of transverse partitions hingedly connected thereto and folded downwardly therefrom between said side walls and on opposite sides of said longitudinal partition to provide a plurality of cushioned article-receiving cells, and supporting means depending from said longitudinal partition below said inner cushioning walls for engagement with said outer bottom sections, said supporting means, inner cushioning walls and outer bottom sections forming a relatively rigid, trusslike support of substantially triangular shape for firmly supporting said inner cushioning bottom walls and longitudinal partition with a smooth outer bottom surface for said carton.

References Cited in the file of this patent UNITED STATES PATENTS 1,836,100 McWilliams Dec. 15, 1931 2,340,753 Inman Feb. 1, 1944 2,374,382 Rutledge Apr. 24, 1945 2,460,020 Lupton Jan. 25, 1949 2,556,088 Inman June 5, 1951 2,634,898 Inman Apr. 14, 1953 

